Continuous-Flow Monolithic Silica Microreactors with Arenesulphonic Acid Groups: Structure–Catalytic Activity Relationships

Copper Oxide Nanoparticles over Hierarchical Silica Monoliths for Continuous-Flow Selective Alcoholysis of Styrene Oxide

A simple and reproducible approach for the synthesis of Cu-based heterogeneous catalysts, named flow chemisorption hydrolysis (flow-CH), is reported. The approach, derived from the CH method, allows size-controlled CuO nanoparticles (mean diameter 2.9 nm) to be obtained, that are highly and homogeneously dispersed into hierarchically meso-/macroporous silica monoliths. The Cu-based monolithic catalysts (CuO@SiO2-MN, 8.4 wt.% Cu) were studied in the styrene oxide ring opening reaction at 60 °C in the presence of isopropanol, under continuous flow-through conditions. A remarkable activity with a steady-state conversion of 97% for 13 h and 100% selectivity towards the corresponding β-alkoxyalcohol was observed. The performances of CuO@SiO2-MN were higher than those obtained in batch conditions with the previously reported CuO/SiO2 catalysts and with the ground CuO@SiO2-MN monolith in terms of productivity and selectivity. Moreover, a negligible Cu leaching (<0.6 wt.%) in reaction medium was observed. After 13 h CuO@SiO2-MN catalysts could be regenerated by a mild calcination (220 °C) permitting reuse.

Recent Advances in Greener and Energy Efficient Alkene Epoxidation Processes

The chemical industry is considered to be one of the largest consumers of energy in the manufacturing sector. As the cost of energy is rising rapidly, coupled with the increasingly stringent standards for the release of harmful chemicals and gases into the environment, more attention is now focused on developing energy efficient chemical processes that could significantly reduce both operational costs and greenhouse gas emissions. Alkene epoxidation is an important chemical process as the resultant epoxides are highly reactive compounds that are used as platform chemicals for the production of commercially important products for flavours, fragrances, paints and pharmaceuticals. A number of epoxidation methods have been developed over the past decade with the ultimate aim of minimising waste generation and energy consumption. In this review paper, some of the recent advances in epoxides synthesis using energy efficient processes are discussed. The epoxidation methods may provide sustainability in terms of environmental impact and energy consumption.

Mass Transfer in Hierarchical Silica Monoliths Loaded With Pt in the Continuous-Flow Liquid-Phase Hydrogenation of p-Nitrophenol

Sol-gel-based silica monoliths with hierarchical mesopores/macropores are promising catalyst support and flow reactors. Here, we report the successful preparation of cylindrically shaped Pt-loaded silica monoliths (length: 2 cm, diameter: 0.5 cm) with a variable mean macropore width of 1, 6, 10, or 27 μm at a fixed mean mesopore width of 17 nm. The Pt-loaded monolithic catalysts were housed in a robust cladding made of borosilicate glass for use as a flow reactor. The monolithic reactors exhibit a permeability as high as 2 μm2 with a pressure drop below 9 bars over a flow rate range of 2–20 cm3 min−1 (solvent: water). The aqueous-phase hydrogenation of p-nitrophenol to p-aminophenol with NaBH4 as a reducing agent was used as a test reaction to study the influence of mass transfer on catalytic activity in continuous flow. No influence of flow rate on conversion at a fixed contact time of 2.6 s was observed for monolithic catalysts with mean macropore widths of 1, 10, or 27 µm. As opposed to earlier studies conducted at much lower flow velocities, this strongly indicates the absence of external mass-transfer limitations or stagnant layer formation in the macropores of the monolithic catalysts.

Catalytic Functionalized Structured Monolithic Micro-/Mesoreactors: Engineering, Properties, and Performance in Flow Synthesis: An Overview and Guidelines

In this review article, we first discussed the development of silica monoliths with hierarchical macro-/mesopore structure and their potential figures of merit as continuous-flow micro-/mesoreactors of up to 30 ml working volume. Making use of the flow hindrance of different pore structures seen from the Darcy law perspective, we discriminated four structures of the monoliths (M1–M4). We then summarized the most important results, mainly from our studies of continuous-flow structured monolithic reactors and rotating bed reactors (RBRs) filled with structured pellets, activated with various catalytic entities and enzymes. The results show that an increase in the flow rate and thus velocity in reactors activated with more conventional catalytic sites has no or a minor positive effect on the apparent reaction rate. On the contrary, in those with the most open structure (M1) and functionalized with enzymes, it could increase by more than two orders of magnitude even at low overpressures. The production systems worked stably for at least 200 h. To conclude, the synthetic system made of the hierarchically structured monoliths, or RBRs filled with structured catalytic pellets, lay the foundation for a new platform for the high-yield production of a wide variety of specialty chemicals, even on a multikilogram scale, in a safe and sustained manner.

Functionalized Silicas for Metal-Free and Metal-Based Catalytic Applications: A Review in Perspective of Green Chemistry

Heterogeneous catalysis plays a key role in promoting green chemistry through many routes. The functionalizable reactive silanols highlight silica as a beguiling support for the preparation of heterogeneous catalysts. Metal active sites anchored on functionalized silica (FS) usually demonstrate the better dispersion and stability due to their firm chemical interaction with FSs. Having certain functional groups in structure, FSs can act as the useful catalysts for few organic reactions even without the need of metal active sites which are termed as the covetous reusable organocatalysts. Magnetic FSs have laid the platform where the effortless recovery of catalysts is realized just using an external magnet, resulting in the simplified reaction procedure. Using FSs of multiple functional groups, we can envisage the shortened reaction pathway and, reduced chemical uses and chemical wastes. Unstable bio-molecules like enzymes have been stabilized when they get chemically anchored on FSs. The resultant solid bio-catalysts exhibited very good reusability in many catalytic reactions. Getting provoked from the green chemistry aspects and benefits of FS-based catalysts, we confer the recent literature and progress focusing on the significance of FSs in heterogeneous catalysis. This review covers the preparative methods, types and catalytic applications of FSs. A special emphasis is given to the metal-free FS catalysts, multiple FS-based catalysts and magnetic FSs. Through this review, we presume that the contribution of FSs to green chemistry can be well understood. The future perspective of FSs and the improvements still required for implementing FS-based catalysts in practical applications have been narrated at the end of this review.

Electric field assisted multicomponent reaction in a microfluidic reactor for superior conversion and yield

We explore the improvements in yield and conversion of a chemical reaction inside a two-phase microfluidic reactor when subjected to an externally applied alternating current (AC) electric field. A computational fluid dynamic (CFD) framework has been developed to incorporate the descriptions of the two-phase flow, multicomponent transport and reaction, and the Maxwell's stresses generated at oil-water interface owing to the presence of the externally applied electric field. The CFD model ensures that the reactants are flown into a microchannel together with the oil and water phases before the reaction takes place at the interface and products diffuse back to the bulk phases. The study unveils that the variation in the intensity of the AC field helps in converting a two-phase stratified flow into an oil-in-water microemulsion composed of oil slugs, plugs, or droplets. Importantly, the results also suggest that harnessing the vortices inside or outside these flow patterns helps in the improvement in mass transfer across the interface, which can be employed to improve the yield and conversion of a reaction. We have shown an example case of a pseudo-first order reaction for which the variation in frequency and intensity of AC field is found to form higher surface-to-volume-ratio flow patterns having a higher throughput. The convective recirculation in and around these miniaturized flow morphologies increase the rate of mass transfer, mixing of reactant and products, conversion of reactant, and yield of products. The results reported can be of significance in the design and development of future advanced-flow rector technologies.

Selective Reduction of Ketones and Aldehydes in Continuous-Flow Microreactor—Kinetic Studies

In this work, the kinetics of Meerwein–Ponndorf–Verley chemoselective reduction of carbonyl compounds was studied in monolithic continuous-flow microreactors. To the best of our knowledge, this is the first report on the MPV reaction kinetics performed in a flow process. The microreactors are a very attractive alternative to the batch reactors conventionally used in this process. The proposed micro-flow system for synthesis of unsaturated secondary alcohols proved to be very efficient and easily controlled. The microreactors had reactive cores made of zirconium-functionalized silica monoliths of excellent catalytic properties and flow characteristics. The catalytic experiments were carried out with the use of 2-butanol as a hydrogen donor. Herein, we present the kinetic parameters of cyclohexanone reduction in a flow reactor and data on the reaction rate for several important ketones and aldehydes. The lack of diffusion constraints in the microreactors was demonstrated. Our results were compared with those from other authors and demonstrate the great potential of microreactor applications in fine chemical and complex intermediate manufacturing.